Method of making metal cross bar joints



June 16, 1953 x 5, M, s, ADAMS 2,641,825

7 METHOD OF MAKING METAL CROSS BAR JOINTS Filed June 22, 1949 4 Sh'eets -Shet 1 WI! 'u a f l 18 ll "n NIH/I u i m" 4 6 EI EI.

E- 5 HTHHHTI HH mii' umn.

15 ,7 ria -41 I/M/e/zfor Jl me 16, 1953 s, s, MS 2,641,825

' METHOD OF MAKING METAL CROSS BAR JOINTS Filed June 22, 1949 4 Sheets-Sheet 2 Q4. 42a 23 11 M 22 ka ma 2% 21!: 2 20 25 nmngy 3% 32 I i'; 36 E P} 5, 36

I I S-lFJ k Wm {In 30 dwfirdflsjgzz; 76 :35 33 76? -1=I le1 *7 June 16, 1953 s. M. s. ADAMS I METHOD MAKING METAL CROSS BAR JOINTS 4 Sheets-Sheet 3 Filed June 22, 1949 5-5m g 51 H mm H M H m i F H I HI" 1 i 46 Hllllll" ried by the other bar.

Patented June 16, 1953 METHO'D'OF MAKING METAL CROSS BAR JOINTS Stafiord'Morley Sidney Adams, Windsor, Ontario, Canada, assignor to Truscon Steel Company of Canada, Limited, Walkerville, Ontario, Canada Application June 22, 1949, Serial No. 100,715

1 Claim. (01. 29-448) This invention relates to improvements in metal bar cross joints and more particularly to a method of interfitting and welding or, otherwise securing the bars together at their joints.

According to the conventional practice, the metal bars to be joined in, crossed relation are slotted to be fitted together, the one bar within the slot of the other in abutting engagement. The bars are then welded or otherwise secured together in abutting engagement without relative movement of the bars. It is, therefore, necessary that the slots in the bars be of a predetermined depth which would permit interfitting of the bars in their desired positions relative to one another before welding. However, it more frequently happens that, due to lack of uniformity of workmanship, there are slight variations either between the bars or slots. In such cases it requires considerable expense in time and labour to adjust the bars to their desired relative positions before welding can be efiected.

A particular object of this invention is to provide a method of joiningv bars. in crossed relation by fitting a portion of one bar. in a slot provided in the other bar, and. then heating and pressing the bars together to causethe contacting portions of the metal in the bars to flow and to weld together. Such contacting portions may constitute the solid portion of the slotted bar located at the inner end of the slot and a portion of the other bar which engages the inner end of the slot. In the case of flanged bars the contacting portions may be formed by the overlapping edge portions of the flanges carried by one bar and by edge portions of the flanges car- As a further modification the contacting portions may be at the base. of

the slots as well as between the overlapping edge of the companion bar and with the flanges and side edges of the bars out of co-planar relation to each other, and then heating and forcing the bars together to cause the metal at the points of contact to flow to bring the flanges and at least one side edge of the bars into co-planar 2 relation and to weld together the contacting portions of the bars with their flanges and side edges in co-planar'relation.

Although the particular application of this invention was conceived as the result of research in the development of a joint for metal cross bars for window frame construction, it is not the intention to limit its application to cross bar joints for window frames but to apply the principle to any metal bars where one bar is received in the slot of a companion bar to be joined together by welding or other similar process.

Proceeding now to a more detailed description, reference will be had to the accompanyin drawings, in which:

Fig. 1 is a top plan view showing a pair of cruciform bars joined together in crossed relation according to my invention.

Figs. 2 and 3 are top plan and side elevational views of one of the bars shown in Fig. 1.

Figs. 4 and 5 are top plan and side elevational views of the other bar.

Fig. 6 is an end view of the bars shown in Fig. 1.

Fig. '7 is a sectional view taken along the lines !l of Fig. 1.

Fig. 8 is a sectional view similar to Fig. '7 but showing the bars offset in assembled relation before the pressure welding operation.

Fig. 9 is a top plan view similar to Fig. 1 but showing a modification in the form of T-shaped bars.

Fig. 10 is an end view of the bars shown in Fig. 9.

Fig. 11 is a sectional view taken along the lines ll-H of Fig. 9.

Fig. 12 is a view similar to Fig. 11 but showing the bars offset in assembled relation prior to the pressure welding operation.

Fig. 13 is a top plan View similar to Fig. 9 but showing a modified form of interfitting of the bars in the flange section.

Figs. 14 and 15 are top plan and side elevational views of one of the bars shown in Fig. 13.

Figs. 16 and 17 are top plan and side elevational views of the other bar.

Fig. 18 is an end view of the bars shown in Fig. 13.

Fig. 19 is a sectional viewtaken along the lines ill-19 of Fig. 13.

Fig. 20 is a view similar to Fig. 19 but showing the bars ofiset in assembled relation prior to the pressure welding operation.

Fig. 21 is a top plan view of cruciform bars offset in assembled relation prior to the pressure welding operation with the mitred edges of the flanges at the joint of one bar overlapping the corresponding edges of the other bar.

Figs. 22 and 23 are top plan and side elevational views of one of the bars shown in Fig. 21.

Figs. 24 and 25 are top plan and side elevational views of the other bar.

Fig. 26 is a sectional View taken along the lines 2626 of Fig. 21.

Fig. 27 is a top plan view showing the bars of Fig. 21 after they have been welded together in coplanar relation.

Fig. 28 is a sectional view taken along the lines 28-28 of Fig. 27. 1

Fig. 29 shows a modification'of the sectional view Fig. 26.

Fig. 30 shows a modification of view of Fig. 28.

the sectional Fig. 31 is a top plan view showing T-shaped bars joined together in the manner shown in Fig. 27.

Fig. 32 is an end View of the bars shown in Fig. 31.

Fig. 33 is a sectional view taken along the lines 3333 of Fig. 31.

Fig. 34 is a sectional view similar to 38 but showing the bars oflset in assembled relation prior to the pressure welding operation.

Fig. 35 is a top plan view showing T-shaped bars similar to the bars in Fig. 13 but showing the bars joined together along the meeting edges of the flanges.

Referring more particularly to the drawings,

Fig. 1 shows a bar cross joint formed by a pair of y cruciform bars 5 and 5 (see Figs. 2 to 5) arranged in interfitting relation at right angles to one another. Bar 5 comprises a central web prtion I with side flanges S on opposite sides thereof,

flanges 8 being closer to the side edge 9 than to the opposite side edge 1 8 of web 5. Web I is pro vided with a slot I2 which extends inwardly from the side edge 9. Bar 6 comprises a central web portion I3 with side flanges is on opposite sides thereof, flanges Hi being closer to the side edge 55 than to the opposite side edge 5 t of web i3. Web It is provided with a slot ll whichextends inwardly from the side edge 56. Flanges 3 and i i are mitred, as indicated at i i and E8, to form a tting mitre joint 19 when the bars are interfltted with the flanges in co-planar relation as shown in Fig. 1.

Bars ii and 6 are first assembled, as shown in Fig. 8 with the solid portion of web is beyond slot :1 received in slot I2 of web 7 and the solid portion of web I beyond slot I2 received in slot ll of web it. The inner ends of slots '52 and H are butted against each other. The depths of slots I2 and ii are predetermined so that, when bars 5 and 5 are first assembled, the side edge iii and the flanges It will be outwardly offset with respect to the side edge 9 and flanges 8. Bars 5 and '6 are then fused or welded at the bases of slots I2 and H, as indicated at 219 (Figs. 6 and '7) by electric welding or other suitable apparatus, pressure being applied to the bars causing the metal to flow in the weld areas i211 and Ila (see Figs. 3 and 5), at the base of the slots until the side edge I5 and flanges i i are in co-p1anar re lation with the side edge 9 and flanges 6 respec tively.

Figs. 9 to 12 show a similar bar cross joint formed by a pair of T-shaped bars 28 and 2!. Bar 26 has a central web 22 with flanges 23 on opposite sides of the web along one side edge.

Web 23 has a slot and weld area corresponding to the slot and weld area l2 and IN of bar 5, said slot intersecting flanges 23 and extending inwardly therefrom. Bar 2I has a central web 25 with flanges 26 on opposite sides of the web along one side edge. The web has a slot and weld area corresponding to the slot and weld area H and I'm of bar'B, said slot extending inwardly from the side edge of the web remote from flanges 26. Flanges 23 and 26 are mitred in the same manner as the flanges of bars 5 and (5 to form a mitre joint 21 when the bars are interfltted and pressure welded together.

Bars 20 and 2| are first assembled as shown in Fig. 12, in the same manner as the bars 5 and B. The bars are then welded at 28. Heat and pressure are then applied to the bars causing the metal to flow in the weld area at the base of the slots until the side edges of the webs and the flanges of each bar are in co-planar relation.

Figs. 13 to 20 show a bar cross joint similar to the previously described joints but with a modifled construction of the T-shaped bars. The joint is formed by a pair of T-shaped bars 3E3 and 3!. Bar 3!? has a central web 32 with flanges 33 on opposite sides of the web along one side edge. Web 32 is provided with a slot 3 which extends inwardly from the edge remote from flanges 33. A weld area in the solid portion of web 22 adjacent the inner end of slot at is indicated at Bar at has a central web 35 with flanges on opposite sides of the web along one side Web 35 is slotted, as indicated at 2i, said siot intersecting flanges 35 and extending inwardl therefrom. The web is provided with a weld area 3m adjacent the inner end of the slot. The intersecting slot in the flanges 355 is equal to the thickness of the web 32 of bar 35} so that their inner edges 33 will be butted against the surfaces of web 32 when the bars are joined together. The flanges 33 of bar 30 are recessed, as indi cated at 39, to receive the flanges 36 of bar 3! therebetween when the bars are joined together.

The bars 32 and 3| are first assembled, as shown in Fig. 20, with the solid portion of web 32 beyond slot 34 received in slot 3? of web 35 and the solid portion of web 35 beyond slot 3? received in slot 34. The inner ends of slots and 3'! are butted against each other. The depth of slots 3 and 37 is such that when barstfl and 2! are first assembled, the flanges 32 will be outwardly oflset with respect to flanges The bars 32 and 3| are then fused or welded at the bases of slots 34 and 37, as indicated at t'ib (see Figs. 18 and 19), at the base of the slots until the flanges are in co-planar relation with the side edges of flanges 36 in the recesses 32 defined by the inner end edges of flanges 36.

In Figs. 21 to 27 I have shown a modified bar cross joint. This joint is formed with cruciform bars 40 and M similar to the bars 5 and 6. An essential difierence consists in mitring the flanges 43 and 47 of bars 40 and M respectively so that the mitred edges 49 of flanges 41 will overlap the mitred edges 45 of flanges 43 when the bars are first assembled, as shown in Fig. 21. Another diflerence consists in elongating the slots 44 and 48 in the webs 42 and 46 so as to form a gap, as indicated at 44c (see Fig. 26) between the inner ends of the slots. The heat and pressure is applied to the bars to form a weld, as indicated at 45a (see Fig. 27) between the mitred edges 45 and 49 of the flanges 43 and 47. This is done by causing the metal in the overlapping portions of the flanges to flow until said flanges are in co-planar relation. When the joint is thus formed, the portions of the webs 42 and 4B defining the inner ends of slots are butted together, as shown in Fig. 28.

In Figs. 29 and 30 I have shown a further modification which is, in effect, a. combination of the welded joint at the base of the slots of the bars and the welded joint in the overlapping mitred edges of the flanges. The bars 50 and 5| are slotted in their web portions 52 and 56 in the same manner as bars 5 and 6 and are provided with a weld area in the web portions beyond their slots. The flanges 53 and 51 are mitred in the joint area similar to the flanges of bars 40 and 4| so that their mitred edges will be in overlapping relation when the bars are first assembled, as shown in Fig. 29. It will also be noted that the inner ends of the slots are butted together in this position. When heat and pressure are applied to the bars welding will take place between the overlapping edges of flanges to form a welded mitred joint indicated at 54 and between the webs adjacent the abutting ends of the slots therein, as indicated at 58 (see Fig. 30).

Figs. 31 to 34 show a modification of the joint shown in connection with bars 40 and 4 I. In this joint, T-shaped bars 60 and 61 similar to the bars 20 and 2! are employed. The bars 60 and 6| have overlapping mitred edges which form a welded joint 64 in the mitred area of the flanges 63 and 61 when the bars are heated and pressed together, as shown in Figs. 31, 32 and 33. The slots in the webs 62 and 56 of bars 60 and 6| are sumcient to provide a gap, indicated at 68 in Fig. 34, between the inner ends of the slots when the bars are first assembled. When the bars are joined together the gap 68 will be closed and the web portions defining the inner end of the slots will be butted together, as shown in Fig. 33.

Fig. 35 shows a still further modification employing T-shaped bars 10 and 1 I of similar construction to the bars 30 and 31. In this joint, the inner edges of flanges I3 defining the recess into which the flanges 11 are received, overlap the edges of flanges 11 so that pressure welding takes place at 14 between said overlapping edges. The webs 12 and 16 are slotted so that the portions of the webs defining the inner ends of the slots will be butted together when the bars are joined with their flanges in co-planar relation.

Having described what I now believe to be the preferred embodiment of this invention, it will be understood that various other modifications in the interfitting arrangement of similar cross joints may be resorted to within the scope and spirit of the invention, as defined in the appended claim. For example, while not shown, the bars may be slotted in their web portion and angularly out in the flange portion to provide interfitting of the cross bars at suitable angles other than at right angles. Pressure welding of the bars would be performed at the base of the slots and/or along the joints of the flanges in the manner heretofore described.

I claim:

A method of joining, in interfitting and intersecting relation, a pair of bars each comprising a central web portion and aligned flanges projecting laterally in opposite directions from the web portion at right angles thereto, said method comprising slotting the flanges of at least one bar to provide for co-planar disposition of the flanges of the two bars at their point of intersection, slotting the web of each bar to provide a slot extending inwardly from one side edge of the web a distance such that, when the webs of the two bars are assembled in crossed interfitting relation with the solid portion at the inner end of the slot of each web contacting the inner end wall of the slot of the companion web, the flanges of one bar will be offset out of co-planar relationship with the flanges of the companion bar, assembling said bars with the webs disposed in the aforesaid crossed relationship, and then subjecting the bars to heat and pressure whereby the metal of the two webs is caused to flow and fuse together at the point of contact located at the inner ends of the slots and whereby the flanges of the two bars are simultaneously forced into co-planar relationship.

STAFFORD MORLEY SIDNEY ADAMS.

References Cited in the file of this patent UNITED STATES PATENTS Number Name Date 1,000,967 Farquhar Aug. 15, 1911 1,301,981 Smith Apr. 29, 1919 1,308,428 Lachman July 1, 1919 1,529,445 Miller Mar. 10, 1925 1,934,765 Julien Nov. 14, 1933 2,241,871 Tench May 13, 1941 

